Process for preparing pouches

ABSTRACT

The present invention relates to a process for preparing water-soluble pouches from at least one sheet of water-soluble film, comprising the step of shaping pouches from said water-soluble film in a series of molds, wherein said molds are positioned in an interlocking manner.

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority under 35 U.S.C. § 119(a) toGreat Britain Application Ser. No. 0028179.0, filed Nov. 17, 2000(Attorney Docket No. CM2448F).

TECHNICAL FIELD OF THE INVENTION

[0002] The present invention relates to a process for preparingwater-soluble pouches. The process minimizes film scrap during thepreparation of water-soluble pouches. The water-soluble pouches maycontain a composition, especially a detergent composition.

BACKGROUND TO THE INVENTION

[0003] Many consumers do not want to come into contact with detergentingredients commonly used and found in detergent products, during thewashing process. The laundry detergent industry has been trying toprevent or minimize the contact between detergent ingredients and theconsumer. For example, the detergent industry developed detergenttablets which minimized the generation of detergent ingredients in theform of dust when handled by a consumer during the washing process.However, these detergent tablets still produce dust when handled byconsumers during the washing process. Thus, there is still a need toprovide a detergent product which can be used by consumers wherein thecontact between the detergent ingredients therein and the consumer isprevented or further minimized.

[0004] Attempts have been made to solve this problem by enclosing thedetergent ingredients with a film, to form a detergent pouch. Thesepouches have been further developed by the laundry industry to improvetheir water-solubility profile and cleaning performance.

[0005] In addition, consumers like the benefits of having unit dosedetergent products, for example detergent tablets and detergent pouches.Many consumers find unit dose detergent products easier and quicker touse during the washing process. For example, by using unit dosedetergent products, the amount of detergent to be used during thewashing process is already pre-selected for the consumer, negating theneed for the consumer to determine, and weight out, the desired amountof detergent product which can be a difficult and time consumingprocedure.

[0006] The film used to make detergent pouches is typically expensive.Current processes for manufacturing detergent pouches are not veryefficient and produce a large amount of film scrap. To provide detergentpouches which the consumer can afford to purchase, there is a need todevelop a process for preparing these pouches which is more efficient,and produces less film scrap.

[0007] The present invention provides a process for preparing poucheswhich minimizes the amount of film scrap during the production ofpouches. This process results in less wastage of film and provides anefficient, cost effective means of producing pouches.

SUMMARY OF THE INVENTION

[0008] The present invention provides a process for preparingwater-soluble pouches from at least one sheet of water-soluble film,comprising the step of shaping pouches from said water-soluble film in aseries of molds, wherein said molds are positioned in an interlockingmanner.

[0009] Preferably, the shape of said molds is a polygon. More preferablythe shape of said molds is a hexagon.

[0010] The present invention also provides a water-soluble pouch,obtainable by a process comprising the step of shaping pouches from awater-soluble film in a series of molds, wherein said molds arepositioned in an interlocking manner, and wherein further the shape ofsaid molds is a hexagon.

[0011] The present invention provides a mold, or series of molds, for awater-soluble pouch, wherein the shape of said mold, is a hexagon.

[0012] The present invention provides a use of a process for preparingwater-soluble pouches from at least one sheet of water-soluble film,comprising the step of shaping pouches from said water-soluble film in aseries of molds, wherein said molds are positioned in an interlockingmanner, to prepare water-soluble pouches.

DETAILED DESCRIPTION OF THE INVENTION

[0013] Series of Molds

[0014] The pouches are made using a series of molds having the sameshape. The molds are positioned in an interlocking manner.

[0015] The shape of the mold is the shape when viewed looking directlyat the indent of the mold.

[0016] The series of molds comprise more than one mold, preferably morethan two molds, or more than three molds, or more than 5 molds, or morethan 7 molds, or more than 10 molds, or more than 15 molds, or more than25 molds, or more than 50 molds, or more than 100 molds. The series ofmolds may comprise molds in one line or in a series of lines. Forexample, the series of molds may be made up by three or four lines ofmolds.

[0017] The molds are typically positioned in an adjacent manner. Themolds are preferably evenly spaced apart.

[0018] Typically, the maximum variation in the distance between theedges of adjoining molds, is less than 200%, preferably less than 150%,or less than 100%, or less than 90%, or less than 80%, or less than 70%,or less than 60%, or less than 50%, or less than 40%, or less than 30%,or less than 20%, or less than 10%, or less than 7%, or less than 5%, orless than 3%, or less than 2%, or less than 1%, or less than 0.5%.

[0019] The molds typically comprise a straight edge or a slightly curvededge. By slightly curved edge, it is typically meant an edge having acurvature of a radius that is greater than 0.5 meters, preferablygreater than 1 meter, or greater than 1.5 meters, or greater than 2meters, or greater than 2.5 meters, or greater than 3 meters, or greaterthan 5 meters, or greater than 7.5 meters, or greater than 10 meters, orgreater than 50 meters, or greater than 100 meters, or greater than 250meters, or greater than 500 meters, or greater than 1000 meters.Preferably, the molds comprise at least one straight edge, morepreferably the molds comprise more than one straight edge, mostpreferably all of the edges of the molds are straight. This allows moldshaving the same shape to interlock more easily, by being able tointerlock via the straight edge.

[0020] Preferably the edges of adjoining molds are substantiallyparallel. Preferably at least one edge of a first mold is substantiallyparallel to at least one edge of a second mold which is positionedadjacently to said first mold, thus the variation in distance betweensaid edges is 0%.

[0021] Leakage of ingredients from the pouch, and ruptures to the filmof the pouch are more likely to occur at the corners of the pouch. Thepouches prepared by the process herein, are more structurally stable andless likely to rupture or leak ingredients, if the molds comprise fewcorners having acute angles. Preferably, the molds comprise less thantwo corners having an internal angle of 90°, more preferably the moldscomprise less than two corners having an internal angle of 90° or less,even more preferably the molds comprise no corners having an internalangle of 90° or less.

[0022] The mold preferably comprises at least one corner, preferablymore than one corner, having an internal angle greater than 90°. Themold preferably comprises at least one corner, preferably more than onecorner, having an internal angle of from 100° to 140°, most preferablyhaving an internal angle of 120°. The mold preferably comprises cornershaving the same angles. The mold preferably comprises more than 4corners, for example, the mold preferably comprises at least 5 corners,or more preferably at least 6 corners. If the corner of the pouch isrounded, then the angle of the corner is the typically the overall angleof the corner.

[0023] The shape of the mold is shape which can interlock with a mold ofthe same shape, to form a series of interlocking shapes. Preferably theshape of the mold is a polygon, preferably a hexagon, square, rectangle,rhombus, triangle, more preferably a hexagon. Most preferably, the moldis a hexagon, wherein the sides of said hexagon are the same size, andwherein the internal angles of the corners of said hexagon are all 120°.

[0024] The bottom of the mold is preferably rounded, the indent of themold is preferably hemispherical-like. This is to minimize the variationof stretch introduced to a film which is pulled flush to the innersurface of the mold. The sides of the mold, which dictate the shape ofthe mold are preferably a series of straight edges.

[0025] The molds are typically of a size having the largestcross-sectional distance across the face of the mold being from 1 cm to50 cm, preferably from 2 cm to 10 cm.

[0026] The mold preferably comprises an indent of a size such that thepouches obtained by the process herein have an internal volume of from 1ml to 200 ml, preferably from 10 ml to 60 ml.

[0027] The molds preferably have a lip around the edge, which allows asource of heat or pressure to be applied around the edge of the moldduring the process herein. Said lip is preferably from 0.01 mm to 10 mm,depending on the size of the mold and is preferably less than 10%, orpreferably less than 9%, or less than 8%, or less than 7%, or less than6% of the largest cross-sectional distance across the face of said mold.

[0028] Typically, if present, this lip can be raised slightly from theedge of the mold. By raising the lip, a stronger seal is formed which isless likely to leak ingredients, if present, from the pouch. This lip,if present, is typically raised from 0.001 mm to 10 mm, preferably from0.01 mm to 0.2 mm.

[0029] The mold can be made by any appropriate material. Typically thematerial of the mold is capable of withstanding the amount of pressureapplied to said mold during the process herein, typically this pressureis from 1×10⁴ Nm⁻² to 1×10⁶ Nm⁻². Typically the material of the mold iscapable of withstanding the heat applied to said mold during theprocess, typically this heat is from 40° C. to 200° C.

[0030] Water-Soluble Film

[0031] The water-soluble film, herein referred to as “film”, typicallythe film is water-dispersible and has a dispersibility of at least 50%,preferably at least 75% or even at least 95%, as measured by thegravimetric method set out hereinafter, using a glass-filter with amaximum pore size of 50 microns.

[0032] More preferably the film is water-soluble and has a solubility ofat least 50%, preferably at least 75% or even at least 95%, as measuredby the gravimetric method set out hereinafter, using a glass-filter witha maximum pore size of 20 microns, namely:

[0033] Gravimetric method for determining water-solubility orwater-dispersibility of the film:

[0034] 50 grams±0.1 gram of film is added in a 400 ml beaker, whereofthe weight has been determined, and 245 ml±1 ml of distilled water isadded. This is stirred vigorously on magnetic stirrer set at 600 rpm,for 30 minutes. Then, the mixture is filtered through a foldedqualitative sintered-glass filter with the pore sizes as defined above(max. 20 or 50 micron). The water is dried off from the collectedfiltrate by any conventional method, and the weight of the remainingpolymer is determined (which is the dissolved or dispersed fraction).Then, the % solubility or dispersibility can be calculated.

[0035] The pouch is made from a water-soluble film. Preferredwater-soluble films are polymeric materials, preferably polymers whichare formed into a film or sheet. The material in the form of a film canfor example be obtained by casting, blow-molding, extrusion or blowextrusion of the polymer material, as known in the art.

[0036] Preferred polymers, copolymers, or derivatives thereof, areselected from polyvinyl alcohols, polyvinyl pyrrolidone, polyalkyleneoxides, acrylamide, acrylic acid, cellulose, cellulose ethers, celluloseesters, cellulose amides, polyvinyl acetates, polycarboxylic acids andsalts, polyaminoacids or peptides, polyamides, polyacrylamide,copolymers of maleic/acrylic acids, polysaccharides including starch andgelatin, natural gums such as xanthum and carragum.

[0037] More preferably the polymer is selected from polyacrylates andwater-soluble acrylate copolymers, methylcellulose,carboxymethylcellulose sodium, dextrin, ethylcellulose, hydroxyethylcellulose, hydroxypropyl methylcellulose, maltodextrin,polymethacrylates, most preferably polyvinyl alcohols, polyvinyl alcoholcopolymers and hydroxypropyl methyl cellulose (HPMC).

[0038] The polymer can have any weight average molecular weight,preferably from about 1000 to 1,000,000, or even form 10,000 to 300,000or even form 15,000 to 200,000 or even form 20,000 to 150,000.

[0039] Mixtures of polymers can also be used. This may in particular bebeneficial to control the mechanical and/or dissolution properties ofthe film, depending on the application thereof and the required needs.For example, it may be preferred that a mixture of polymers is presentin the film, whereby one polymer material has a higher water-solubilitythan another polymer material, and/or one polymer material has a highermechanical strength than another polymer material. It may be preferredthat a mixture of polymers is used, having different weight averagemolecular weights, for example a mixture of PVA or a copolymer thereofof a weight average molecular weight of 10,000-40,000, preferably around20,000, and of PVA or copolymer thereof, with a weight average molecularweight of about 100,000 to 300,000, preferably around 150,000.

[0040] Also useful are polymer blend compositions, for examplecomprising hydrolytically degradable and water-soluble polymer blendsuch as polylactide and polyvinyl alcohol, achieved by the mixing ofpolylactide and polyvinyl alcohol, typically comprising 1-35% by weightpolylactide and approximately from 65% to 99% by weight polyvinylalcohol, if the material is to be water-dispersible, or water-soluble.

[0041] It may be preferred that the polymer present in the film is from60% to 98% hydrolysed, preferably 80% to 90%, to improve the dissolutionof the material.

[0042] Suitable examples of commercially available water-soluble filmsinclude polyvinyl alcohol and partially hydrolysed polyvinyl acetate,alginates, cellulose ethers such as carboxymethylcellulose andmethylcellulose, polyethylene oxide, polyacrylates and combinationsthereof. Most preferred are films which comprises PVA polymers and havesimilar properties to films that are known under the trade referenceM8630, as sold by Chris-Craft Industrial Products of Gary, Indiana, US.Other preferred films suitable for use herein have similar properties tofilms that are known under the trade reference PT film or the K-seriesof films supplied by Aicello, or VF-HP film supplied by Kuraray.

[0043] The film herein may comprise other additive ingredients than thepolymer or polymer material. For example, it may be beneficial to addplasticisers, for example glycerol, ethylene glycol, diethyleneglycol,propylene glycol, sorbitol and mixtures thereof, additional water,disintegrating aids. It may be useful when the pouched composition is adetergent composition, that the pouch or compartment material itselfcomprises a detergent additive to be delivered to the wash water, forexample organic polymeric soil release agents, dispersants, dye transferinhibitors.

[0044] Process

[0045] The process for preparing water-soluble pouches, herein referredto as “the process” comprises the step of shaping pouches from saidwater-soluble film in a series of molds, wherein said molds arepositioned in an interlocking manner.

[0046] By shaping, it is typically meant that the water soluble film isplaced onto and into the molds, for example, the film may be vacuumpulled into the molds, so that said film is flush with the inner wallsof the molds. This is commonly known as vacuum forming. Anotherpreferred method is thermo-forming to get the film to adopt the shape ofthe mold.

[0047] Thermo-forming typically involves the step of formation of anopen pouch in a mold under application of heat, which allows the filmused to make the pouches to take on the shape of the molds.

[0048] Vacuum-forming typically involves the step of applying a(partial) vacuum (reduced pressure) on a mold which sucks the film intothe mold and ensures the film adopts the shape of the mold. The pouchforming process may also be done by first heating the film and thenapplying reduced pressure, e.g. (partial) vacuum.

[0049] The film is typically sealed by any sealing means. For example,by heat sealing, wet sealing or by pressure sealing. In a preferredembodiment, a sealing source is contacted to the film and heat orpressure is applied to the film, and the film is sealed. The sealingsource may be a solid object, for example a metal, plastic or woodobject. If heat is applied to the film during the sealing process, thensaid sealing source is typically heated to a temperature of from 40° C.to 200° C. If pressure is applied to the film during the sealingprocess, then the sealing source typically applies a pressure of from1×10⁴ Nm⁻² to 1×10⁶ Nm⁻², to the film.

[0050] The same piece of film may be folded, and sealed to form pouches.Typically more than piece of film is used in the process herein. Forexample, a first piece of the water soluble film may be vacuum pulledinto the molds so that said film is flush with the inner walls of themolds. A second piece of water-soluble film may be positioned such thatit at least partially overlaps, preferably completely overlaps, with thefirst piece of film. The first piece of film and second piece of filmare sealed together. The first piece of film and second piece of filmcan be the same type of film or can be different types of film.

[0051] If the pouches obtained from the process herein contain acomposition, then in a preferred embodiment of the present invention, afirst piece of the water soluble film may be vacuum pulled into themolds so that said film is flush with the inner walls of the molds. Acomposition may be poured into the molds, and a second water-solublefilm may be placed over the molds with the composition and the firstpiece of film and second piece of film are sealed together to formpouches, typically in such a manner as to at least partially enclose,preferably completely enclose, the composition.

[0052] Preferably the first film is stretched, as defined hereinafter.Typically, the second film is not as stretched as the first film.

[0053] Preferably, the first film has an unstretched thickness of from50 micrometers to 200 micrometers, preferably from 60 micrometers, orfrom 70 micrometers, and preferably to 150 micrometers, or to 100micrometers, or to 90 micrometers, or to 80 micrometers. Preferably thesecond film has an unstretched thickness of from 5 micrometers to 40micrometers, preferably from 10 micrometers, or from 20 micrometers, orfrom 30 micrometers.

[0054] It may be preferred that the film, and preferably the pouch as awhole, is stretched during formation of the pouch, such that theresulting pouch is at least partially stretched. This is to reduce theamount of film required to enclose the volume space of the pouch.

[0055] When the film is stretched the film thickness decreases. Thedegree of stretching indicates the amount of stretching of the film bythe reduction in the thickness of the film. For example, if bystretching the film, the thickness of the film is exactly halved thenthe stretch degree of the stretched film is 100%. Also, if the film isstretched so that the film thickness of the stretched film is exactly aquarter of the thickness of the unstretched film then the stretch degreeis exactly 200%. Typically and preferably, the thickness and hence thedegree of stretching is non-uniform over the pouch, due to the formationand closing process. For example, when a water-soluble film ispositioned in a mold and an indent is formed by vacuum forming (and thenfilled with the components of a composition and then closed), the partof the film in the bottom of the mold, furthest removed from the pointsof closing will be stretched more than in the top part. Preferably, thefilm which is furthest away from the opening, e.g. the film in thebottom of the mold, will be stretched more and be thinner than the filmclosest by the opening, e.g. at the top part of the mold.

[0056] Another advantage of stretching the film, is that the stretchingaction, when forming the shape of the pouch and/or when closing thepouch, stretches the pouch non-uniformly, which results in a pouch whichhas a non-uniform thickness. This allows control of the dissolution ofwater-soluble pouches herein, and for example, sequential release of thecomponents of a detergent composition enclosed by the pouch to thewater.

[0057] Preferably, the pouch is stretched such that the thicknessvariation in the pouch formed of the stretched water-soluble film isfrom 10 to 1000%, preferably 20% to 600%, or even 40% to 500% or even60% to 400%. This can be measured by any method, for example by use ofan appropriate micrometer. Preferably the pouch is made from awater-soluble film that is stretched, said film has a stretch degree offrom 40% to 500%, preferably from 40% to 200%.

[0058] The process herein may be used to prepare pouches which have aninternal volume that is divided into more than one compartment,typically known as a multi-compartment pouches. In this preferredprocess, the film is folded at least twice, or at least three pieces offilm are used, or at least two pieces of film are used wherein at leastone piece of film is folded at least once. The third piece of film, or afolded piece of film, creates a barrier layer that, when the pouch issealed, divides the internal volume of said pouch into at least twocompartments.

[0059] The process herein can be used to prepare water-solublemulti-compartment pouches by, fitting a first piece of the water solublefilm into a series of molds, for example the first piece of film may bevacuum pulled into the molds so that said film is flush with the innerwalls of the molds. A composition is typically poured into the molds. Apre-sealed compartment made of a water-soluble film can then be placedover the molds containing the composition. These pre-sealed compartmentsand said first piece of film may be sealed together to formmulti-compartment pouches, for example, dual-compartment pouches.

[0060] Pouch Obtained Therefrom

[0061] The pouches obtained from the process herein are water-soluble.Water-soluble typically being determined by the gravimetric methoddescribed hereinbefore.

[0062] The pouch is typically a closed structure, made of awater-soluble film described herein, typically enclosing a volume spacewhich preferably comprises a composition. Said composition is describedin more detail hereinafter. This is preferably suitable to hold acomposition, e.g. without allowing the release of the composition fromthe pouch prior to contact of the pouch to water. The exact executionwill depend on for example, the type and amount of the composition inthe pouch, the number of compartments in the pouch, the characteristicsrequired from the pouch to hold, protect and deliver or release thecompositions.

[0063] The volume space of the pouch can be divided into more than onecompartment. Pouches having a volume space which is divided into morethan one compartment are herein referred to as multi-compartmentpouches. If these multi-compartment pouches contain a composition, thendifferent compartments may contain different ingredients of thecomposition. For example, incompatible ingredients may be contained indifferent compartments.

[0064] The pouches may be of such a size that it conveniently containseither a unit dose amount of the composition herein, suitable for therequired operation, for example one wash, or only a partial dose, toallow the consumer greater flexibility to vary the amount used, forexample depending on the size and/or degree of soiling of the wash load.The shape and size of the pouch is typically determined, at least tosome extent, by the shape and size of the mold.

[0065] Composition Contained Therein

[0066] The pouch typically comprises a composition, typically saidcomposition is contained in the inner volume space of the pouch.

[0067] The compositions herein are cleaning compositions or fabric carecompositions, preferably hard surface cleaners, more preferably laundryor dish washing compositions, including pre-treatment or soakingcompositions and rinse additive compositions.

[0068] Typically, the composition comprises such an amount of a cleaningcomposition, that one or a multitude of the pouched compositions is orare sufficient for one wash.

[0069] The composition can contain any active cleaning ingredient.Particularly preferred are active ingredients such as chelating agents,builders, enzymes, perfumes, bleaches, bleach activators, fabricsofteners, fabric conditioners, surfactants, other fabric conditioners,antibacterial agents, effervescence sources, brighteners,photo-bleaches. Fabric care compositions preferably comprise at leastone or more softening agents, such as quaternary ammonium compoundsand/or softening clays, and preferably additional agent such asanti-wrinkling aids, perfumes and chelating agents.

[0070] Preferably the composition comprises a chelating agent. It isalso preferred that the composition is free from borate. Preferably, thecomposition comprises at least one surfactant and at least one buildingagent.

[0071] It may be possible that part or all of the components of thecomposition are not pre-granulated, such as agglomerated, spray-dried,extruded, prior to incorporation into the compartment, and that thecomposition is a mixture of dry-mixed powder ingredients or even rawmaterials. Preferred may be that for example less than 60% or even lessthan 40% or even less than 20% of the component is a free-flowablepre-granulated granules.

[0072] If the pouches obtained by the process herein comprise more thanone compartment, then incompatible ingredients of a compositioncontained by said pouches, if present, may be contained in differentcompartments.

[0073] Preferred Ingredients of the Composition

[0074] The preferred amounts of ingredients described herein are % byweight of the composition herein as a whole.

[0075] Detersive Surfactants

[0076] Nonionic Alkoxylated Surfactant

[0077] Essentially any alkoxylated nonionic surfactants can be comprisedby the composition herein. These nonionic surfactants are in addition tothe alkoxylated compound of the invention. The ethoxylated andpropoxylated nonionic surfactants are preferred. Preferred alkoxylatedsurfactants can be selected from the classes of the nonionic condensatesof alkyl phenols, nonionic ethoxylated alcohols, nonionicethoxylated/propoxylated fatty alcohols, nonionic ethoxylate/propoxylatecondensates with propylene glycol, and the nonionic ethoxylatecondensation products with propylene oxide/ethylene diamine adducts.

[0078] Highly preferred are nonionic alkoxylated alcohol surfactants,being the condensation products of aliphatic alcohols with from 1 to 75moles of alkylene oxide, in particular about 50 or from 1 to 15 moles,preferably to 11 moles, particularly ethylene oxide and/or propyleneoxide, are highly preferred nonionic surfactants. The alkyl chain of thealiphatic alcohol can either be straight or branched, primary orsecondary, and generally contains from 6 to 22 carbon atoms.Particularly preferred are the condensation products of alcohols havingan alkyl group containing from 8 to 20 carbon atoms with from 2 to 9moles and in particular 3 or 5 moles, of ethylene oxide per mole ofalcohol.

[0079] Nonionic Polyhydroxy Fatty Acid Amide Surfactant

[0080] Polyhydroxy fatty acid amides are highly preferred nonionicsurfactant comprised by the composition, in particular those having thestructural formula R²CONR¹Z wherein: R1 is H, C₁₋₁₈, preferably C₁-C₄hydrocarbyl, 2-hydroxy ethyl, 2-hydroxy propyl, ethoxy, propoxy, or amixture thereof, preferable C1-C4 alkyl, more preferably C₁ or C₂ alkyl,most preferably C₁ alkyl (i.e., methyl); and R₂ is a C₅-C₃₁ hydrocarbyl,preferably straight-chain C₅-C₁₉ or C₇-C₁₉ alkyl or alkenyl, morepreferably straight-chain C₉-C₁₇ alkyl or alkenyl, most preferablystraight-chain C₁₁-C₁₇ alkyl or alkenyl, or mixture thereof; and Z is apolyhydroxyhydrocarbyl having a linear hydrocarbyl chain with at least 3hydroxyls directly connected to the chain, or an alkoxylated derivative(preferably ethoxylated or propoxylated) thereof. Z preferably will bederived from a reducing sugar in a reductive amination reaction; morepreferably Z is a glycityl.

[0081] A highly preferred nonionic polyhydroxy fatty acid amidesurfactant for use herein is a C₁₂-C₁₄, a C₁₅-C₁₇ and/or C₁₆-C₁₈ alkylN-methyl glucamide.

[0082] It may be particularly preferred that the composition hereincomprises a mixture of a C₁₂-C₁₈ alkyl N-methyl glucamide andcondensation products of an alcohol having an alkyl group containingfrom 8 to 20 carbon atoms with from 2 to 9 moles and in particular 3 or5 moles, of ethylene oxide per mole of alcohol.

[0083] The polyhydroxy fatty acid amide can be prepared by any suitableprocess. One particularly preferred process is described in detail in WO9206984. A product comprising about 95% by weight polyhydroxy fatty acidamide, low levels of undesired impurities such as fatty acid esters andcyclic amides, and which is molten typically above about 80° C., can bemade by this process.

[0084] Nonionic Fatty Acid Amide Surfactant

[0085] Fatty acid amide surfactants or alkoxylated fatty acid amides canalso be comprised by the composition herein. They include those havingthe formula: R⁶CON(R⁷)(R⁸ ) wherein R⁶ is an alkyl group containing from7 to 21, preferably from 9 to 17 carbon or even 11 to 13 carbon atomsand R⁷ and R⁸ are each individually selected from the group consistingof hydrogen, C₁-C₄ alkyl, C₁-C₄ hydroxyalkyl, and —(C₂H₄O)_(x)H, where xis in the range of from 1 to 11, preferably 1 to 7, more preferably form1-5, whereby it may be preferred that R⁷ is different to R⁸, one havingx being 1 or 2, one having x being from 3 to 11 or preferably 5.

[0086] Nonionic Alkyl Esters of Fatty Acid Surfactant

[0087] Alkyl esters of fatty acids can also be comprised by thecomposition herein. They include those having the formula: R⁹COO(R¹⁰)wherein R⁹ is an alkyl group containing from 7 to 21, preferably from 9to 17 carbon or even 11 to 13 carbon atoms and R¹⁰ is a C₁ -C₄ alkyl, C₁-C₄ hydroxyalkyl, or —(C₂H₄O)_(x)H, where x is in the range of from 1 to11, preferably 1 to 7, more preferably form 1-5, whereby it may bepreferred that R¹⁰ is a methyl or ethyl group.

[0088] Nonionic Alkylpolysaccharide Surfactant

[0089] Alkylpolysaccharides can also be comprised by the compositionherein, such as those disclosed in U.S. Pat. No. 4,565,647, Llenado,issued Jan. 21, 1986, having a hydrophobic group containing from 6 to 30carbon atoms and a polysaccharide, e.g., a polyglycoside, hydrophilicgroup containing from 1.3 to 10 saccharide units.

[0090] Preferred alkylpolyglycosides have the formula

R²O(C_(n)H_(2n)O)t(glycosyl)_(x)

[0091] wherein R² is selected from the group consisting of alkyl,alkylphenyl, hydroxyalkyl, hydroxyalkylphenyl, and mixtures thereof inwhich the alkyl groups contain from 10 to 18 carbon atoms; n is 2 or 3;t is from 0 to 10, and x is from 1.3 to 8. The glycosyl is preferablyderived from glucose.

[0092] Polyethylene Propylene Glycols

[0093] The composition herein may comprise polyethylene and/or propyleneglycol, particularly those of molecular weight 1000-10000, moreparticularly 2000 to 8000 and most preferably about 4000.

[0094] Anionic Surfactant

[0095] The composition herein, preferably comprises one or more anionicsurfactants. Any anionic surfactant useful for detersive purposes issuitable. Examples include salts (including, for example, sodium,potassium, ammonium, and substituted ammonium salts such as mono-, di-and triethanolamine salts) of the anionic sulphate, sulphonate,carboxylate and sarcosinate surfactants. Anionic sulphate surfactantsare preferred.

[0096] Other anionic surfactants include the isethionates such as theacyl isethionates, N-acyl taurates, fatty acid amides of methyl tauride,alkyl succinates and sulfosuccinates, monoesters of sulfosuccinate(especially saturated and unsaturated C₁₂-C₁₈ monoesters) diesters ofsulfosuccinate (especially saturated and unsaturated C₆-C₁₄ diesters),N-acyl sarcosinates. Resin acids and hydrogenated resin acids are alsosuitable, such as rosin, hydrogenated rosin, and resin acids andhydrogenated resin acids present in or derived from tallow oil.

[0097] Anionic Sulphate Surfactant

[0098] Anionic sulphate surfactants suitable for use herein include thelinear and branched primary and secondary alkyl sulphates, alkylethoxysulphates, fatty oleoyl glycerol sulphates, alkyl phenol ethyleneoxide ether sulphates, the C₅-C₁₇ acyl-N-(C₁-C₄ alkyl and —N—(C₁-C₂hydroxyalkyl) glucamine sulphates, and sulphates of alkylpolysaccharidessuch as the sulphates of alkylpolyglucoside (the nonionic non-sulphatedcompounds being described herein).

[0099] Alkyl sulphate surfactants are preferably selected from thelinear and branched primary C₉-C₂₂ alkyl sulphates, more preferably theC₁₁-C₁₅ branched chain alkyl sulphates and the C₁₂-C₁₄ linear chainalkyl sulphates.

[0100] Alkyl ethoxysulfate surfactants are preferably selected from thegroup consisting of the C₁₀-C₁₈ alkyl sulphates which have beenethoxylated with from 0.5 to 50 moles of ethylene oxide per molecule.More preferably, the alkyl ethoxysulfate surfactant is a C₁₁-C₁₈, mostpreferably C₁₁-C₁₅ alkyl sulphate which has been ethoxylated with from0.5 to 7, preferably from 1 to 5, moles of ethylene oxide per molecule.

[0101] Anionic Sulphonate Surfactant

[0102] Anionic sulphonate surfactants suitable for use herein includethe salts of C₅-C₂₀ linear or branched alkylbenzene sulphonates, alkylester sulphonates, in particular methyl ester sulphonates, C₆-C₂₂primary or secondary alkane sulphonates, C₆-C₂₄ olefin sulphonates,sulphonated polycarboxylic acids, alkyl glycerol sulphonates, fatty acylglycerol sulphonates, fatty oleyl glycerol sulphonates, and any mixturesthereof.

[0103] Anionic Carboxylate Surfactant

[0104] Suitable anionic carboxylate surfactants include the alkyl ethoxycarboxylates, the alkyl polyethoxy polycarboxylate surfactants and thesoaps (‘alkyl carboxyls’), especially certain secondary soaps asdescribed herein.

[0105] Suitable alkyl ethoxy carboxylates include those with the formulaRO(CH₂CH₂O)_(x)CH₂COO⁻M⁺ wherein R is a C₆ to C₁₈ alkyl group, x rangesfrom 0 to 10, and the ethoxylate distribution is such that, on a weightbasis, the amount of material where x is 0 is less than 20% and M is acation. Suitable alkyl polyethoxy polycarboxylate surfactants includethose having the formula RO—(CHR₁—CHR₂—O)_(X)—R₃ wherein R is a C₆ toC₁₈ alkyl group, x is from 1 to 25, R₁ and R₂ are selected from thegroup consisting of hydrogen, methyl acid radical, succinic acidradical, hydroxysuccinic acid radical, and mixtures thereof, and R₃ isselected from the group consisting of hydrogen, substituted orunsubstituted hydrocarbon having between 1 and 8 carbon atoms, andmixtures thereof.

[0106] Suitable soap surfactants include the secondary soap surfactantswhich contain a carboxyl unit connected to a secondary carbon. Preferredsecondary soap surfactants for use herein are water-soluble membersselected from the group consisting of the water-soluble salts of2-methyl-1-undecanoic acid, 2-ethyl-1-decanoic acid, 2-propyl-1-nonanoicacid, 2-butyl-1-octanoic acid and 2-pentyl-1-heptanoic acid. Certainsoaps may also be included as suds suppressers.

[0107] Alkali Metal Sarcosinate Surfactant

[0108] Other suitable anionic surfactants are the alkali metalsarcosinates of formula R—CON(R¹)CH₂COOM, wherein R is a C₅-C₁₇ linearor branched alkyl or alkenyl group, R¹ is a C₁-C₄ alkyl group and M isan alkali metal ion. Preferred examples are the myristyl and oleoylmethyl sarcosinates in the form of their sodium salts.

[0109] Cationic Surfactant

[0110] Another preferred surfactant is a cationic surfactant, which maypreferably be present at a level of from 0. 1% to 60% by weight of thecomposition herein, more preferably from 0.4% to 20%, most preferablyfrom 0.5% to 5% by weight of the composition herein.

[0111] When present, the ratio of the anionic surfactant to the cationicsurfactant is preferably from 35:1 to 1:3, more preferably from 15:1 to1:1. most preferably from 10:1 to 1:1.

[0112] Preferably the cationic surfactant is selected from the groupconsisting of cationic ester surfactants, cationic mono-alkoxylatedamine surfactants, cationic bis-alkoxylated amine surfactants andmixtures thereof.

[0113] Amphoteric Surfactant

[0114] Suitable amphoteric surfactants for use herein include the amineoxide surfactants and the alkyl amphocarboxylic acids.

[0115] Zwitterionic Surfactant

[0116] Zwitterionic surfactants can also be comprised by the compositionherein. These surfactants can be broadly described as derivatives ofsecondary and tertiary amines, derivatives of heterocyclic secondary andtertiary amines, or derivatives of quaternary ammonium, quaternaryphosphonium or tertiary sulfonium compounds. Betaine and sultainesurfactants are exemplary zwitterionic surfactants for use herein.

[0117] Water-Soluble Building Agent

[0118] The composition herein may comprises a water-soluble buildingagent, typically present at a level of from 0% to 36% by weight,preferably from 1% to 35% by weight, more preferably from 10% to 35%,even more preferably from 12% to 30% by weight of the composition orparticle. Preferably, the water-soluble builder compound is an alkali orearth alkali metal salt of phosphate present at the level describedabove.

[0119] Suitable examples of water-soluble phosphate builders are thealkali metal tripolyphosphates, sodium, potassium and ammoniumpyrophosphate, sodium and potassium and ammonium pyrophosphate, sodiumand potassium orthophosphate, sodium polymeta/phosphate in which thedegree of polymerisation ranges from about 6 to 21, and salts of phyticacid.

[0120] Other typical water-soluble building agents include the watersoluble monomeric polycarboxylates, or their acid forms, homo orcopolymeric polycarboxylic acids or their salts in which thepolycarboxylic acid comprises at least two carboxylic radicals separatedfrom each other by not more that two carbon atoms, borates, phosphates,and mixtures of any of the foregoing.

[0121] Water Insoluble Building Agent

[0122] The composition herein preferably comprises a water-insolublebuilding agent. Examples of water insoluble builders include the sodiumaluminosilicates.

[0123] Suitable aluminosilicate zeolites have the unit cell formulaNa_(z)[(AlO₂)_(z)(SiO₂)y]. xH₂O wherein z and y are at least 6; themolar ratio of z to y is from 1.0 to 0.5 and x is at least 5, preferablyfrom 7.5 to 276, more preferably from 10 to 264. The aluminosilicatematerial are in hydrated form and are preferably crystalline, containingfrom 10% to 28%, more preferably from 18% to 22% water in bound form.

[0124] Peroxide Source

[0125] Another preferred ingredient is a perhydrate bleach, such assalts of percarbonates, particularly the sodium salts, and/or organicperoxyacid bleach precursor. It has been found that when the pouch orcompartment is formed from a material with free hydroxy groups, such asPVA, the preferred bleaching agent comprises a percarbonate salt and ispreferably free form any perborate salts or borate salts. It has beenfound that borates and perborates interact with these hydroxy-containingmaterials and reduce the dissolution of the materials and also result inreduced performance.

[0126] Inorganic perhydrate salts are a preferred source of peroxide.Preferably these salts are present at a level of from 0.01% to 50% byweight, more preferably of from 0.5% to 30% by weight of the compositionor component.

[0127] Examples of inorganic perhydrate salts include percarbonate,perphosphate, persulfate and persilicate salts. The inorganic perhydratesalts are normally the alkali metal salts. The inorganic perhydrate saltmay be included as the crystalline solid without additional protection.For certain perhydrate salts however, the preferred executions of suchgranular compositions utilize a coated form of the material whichprovides better storage stability for the perhydrate salt in thegranular product. Suitable coatings comprise inorganic salts such asalkali metal silicate, carbonate or borate salts or mixtures thereof, ororganic materials such as waxes, oils, or fatty soaps.

[0128] Alkali metal percarbonates, particularly sodium percarbonate arepreferred perhydrates herein. Sodium percarbonate is an additioncompound having a formula corresponding to 2Na₂CO₃.3H₂O₂, and isavailable commercially as a crystalline solid.

[0129] Potassium peroxymonopersulfate is another inorganic perhydratesalt of use in the compositions herein.

[0130] Bleach Activator

[0131] The composition herein preferably comprises a bleach activator,preferably comprising an organic peroxyacid bleach precursor. It may bepreferred that the composition comprises at least two peroxy acid bleachprecursors, preferably at least one hydrophobic peroxyacid bleachprecursor and at least one hydrophilic peroxy acid bleach precursor, asdefined herein. The production of the organic peroxyacid occurs then byan in situ reaction of the precursor with a source of hydrogen peroxide.

[0132] The bleach activator may alternatively, or in addition comprise apreformed peroxy acid bleach.

[0133] Preferably, at least one of the bleach activators, preferably aperoxy acid bleach precursor having an average particle size, by weight,of from 600 microns to 1400 microns, preferably from 700 microns to 1100microns is present in the composition herein.

[0134] Hereby, it may be preferred that at least 80%, preferably atleast 90% or even at least 95% or even substantially 100% of thecomponent or components comprising the bleach activator have a particlesize of from 300 microns to 1700 microns, preferably from 425 microns to1400 microns.

[0135] The hydrophobic peroxy acid bleach precursor preferably comprisesa compound having a oxy-benzene sulphonate group, preferably NOBS, DOBS,LOBS and/or NACA-OBS, as described herein.

[0136] The hydrophilic peroxy acid bleach precursor preferably comprisesTAED, as described herein.

[0137] Organic Peroxyacid Bleaching System

[0138] The composition herein preferably comprises an organic peroxyacidprecursor. The production of the organic peroxyacid may occur by an insitu reaction of such a precursor with the percarbonate source. In analternative preferred execution a pre-formed organic

[0139] Chelating Agents

[0140] The composition herein, preferably comprises a chelating agent.By chelating agent it is meant herein components which act to sequester(chelate) heavy metal ions. These components may also have calcium andmagnesium chelation capacity, but preferentially they show selectivityto binding heavy metal ions such as iron, manganese and copper.

[0141] Chelating agents are generally present at a level of from 0.05%to 2%, preferably from 0.1% to 1.5%, more preferably from 0.25% to 1.2%and most preferably from 0.5% to 1% by weight of the composition herein.

[0142] Enzyme

[0143] Another preferred optional ingredient useful in the compositionherein, is one or more additional enzymes.

[0144] Preferred additional enzymatic materials include the commerciallyavailable lipases, cutinases, amylases, neutral and alkaline proteases,esterases, cellulases, pectinases, lactases and peroxidasesconventionally incorporated into compositions. Suitable enzymes arediscussed in U.S. Pat. Nos. 3,519,570 and 3,533,139.

[0145] Suds Suppressing System

[0146] The composition may comprise a suds suppresser at a level lessthan 10%, preferably 0.001% to 10%, preferably from 0.01% to 8%, mostpreferably from 0.05% to 5%, by weight of the composition Preferably thesuds suppresser is either a soap, paraffin, wax, or any combinationthereof. If the suds suppresser is a suds suppressing silicone, then thedetergent composition preferably comprises from 0.005% to 0.5% by weighta suds suppressing silicone.

[0147] Suitable suds suppressing systems for use herein may compriseessentially any known antifoam compound, including, for example siliconeantifoam compounds and 2-alkyl alcanol antifoam compounds.

[0148] By antifoam compound it is meant herein any compound or mixturesof compounds which act such as to depress the foaming or sudsingproduced by a solution of the composition herein, particularly in thepresence of agitation of that solution.

[0149] Particularly preferred antifoam compounds for use herein aresilicone antifoam compounds defined herein as any antifoam compoundincluding a silicone component. Such silicone antifoam compounds alsotypically contain a silica component. The term “silicone” as usedherein, and in general throughout the industry, encompasses a variety ofrelatively high molecular weight polymers containing siloxane units andhydrocarbyl group of various types. Preferred silicone antifoamcompounds are the siloxanes, particularly the polydimethylsiloxaneshaving trimethylsilyl end blocking units. Preferably the compositionherein comprises from 0.005% to 0.5% by weight suds suppressingsilicone.

[0150] Polymeric Dye Transfer Inhibiting Agents

[0151] The composition herein may also comprise from 0.01% to 10%,preferably from 0.05% to 0.5% by weight of polymeric dye transferinhibiting agents. These polymeric dye transfer inhibiting agents are inaddition to the polymeric material of the water-soluble film.

[0152] The polymeric dye transfer inhibiting agents are preferablyselected from polyamine N-oxide polymers, copolymers ofN-vinylpyrrolidone and N-vinylimidazole, polyvinylpyrrolidonepolymers orcombinations thereof.

[0153] Cationic Fabric Softening Agents

[0154] Cationic fabric softening agents are preferably present in thecomposition herein. Suitable cationic fabric softening agents includethe water insoluble tertiary amines or dilong chain amide materials asdisclosed in GB-A-1 514 276 and EP-B-0 011 340. Preferably, thesewater-insoluble tertiary amines or dilong chain amide materials arecomprised by the solid component of the composition herein.

[0155] Cationic fabric softening agents are typically incorporated attotal levels of from 0.5% to 15% by weight, normally from 1% to 5% byweight.

[0156] Other Optional Ingredients

[0157] Other optional ingredients suitable for inclusion in thecomposition herein include optical brighteners, perfumes, colours andfiller salts, with sodium sulphate being a preferred filler salt.

EXAMPLES

[0158] Abbreviations Used in Examples

[0159] In the detergent compositions, the abbreviated componentidentifications have the following meaning: Abbreviation DescriptionAlkoxylated alcohol: Tallow alcohol ethylene oxide condensate of typetallow alcohol, condensed with an average of from 50 to 100 moles ofethylene oxide CxyAS: Sodium C_(1x)-C_(1y) alkyl sulphate CxyEz:C_(1x)-C_(1y) predominantly linear primary alcohol condensed with anaverage of z moles of ethylene oxide CxyEzS: Sodium C_(1x)-C_(1y) alkylsulfate condensed with z moles of ethylene oxide FAS: Fatty alkylsulfate LAS: Sodium linear C₁₁-C₁₃ alkyl benzene sulfonate QAS(1):R₂.N⁺(CH₃)₂(C₂H₄OH), wherein R₂ = C₁₂-C₁₄ QAS(2): R₂.N⁺(CH₃)₂(C₂H₄OH),wherein R₂ = C₈-C₁₁ Carbonate: Anhydrous sodium carbonate Silicate:Amorphous sodium silicate (SiO₂:Na₂O = from 2:1 to 4:1) Sulfate:Anhydrous sodium sulfate Citric acid: Anhydrous citric NaSKS-6:Crystalline layered silicate of formula d-Na₂Si₂O₅ STPP: Anhydroussodium tripolyphosphate Zeolite A: Hydrated sodium aluminosilicate offormula Na₁₂(AlO₂SiO₂)₁₂.27H2O having a primary particle size in therange of from 0.1 to 10 micrometers (weight expressed on an anhydrousbasis) DTPA: Diethylene triamine pentaacetic acid DTPMP: Diethylenetriamine penta(methylene phosphonate), supplied by Monsanto under thetradename Dequest 2060. EDDS: Ethylenediamine-N′N′-disuccinic acid,(S,S) isomer in the form of a sodium salt HEDP: 1,1-hydroxyethanediphosphonic acid Mg sulfate: Anhydrous magnesium sulfate Percarbonate:Sodium percarbonate of the nominal formula 2Na₂CO₃.3H₂O₂ NAC-OBS:(6-nonamidocaproyl) oxybenzene sulfonate NOBS: Nonanoyloxybenzenesulfonate TAED: Tetraacetylethylenediamine Photobleach(1): Sulfonatedzinc phthalocyanine Photobleach(2): Sulfonated alumino phthalocyanineBrightener(1): Disodium 4,4′-bis-(2-sulfostyryl)biphenyl, supplied byCiba-Geigy under the tradename Tinopal CBS Brightener(2): Disodium4,4′-bis-((4-anilino-6-morpholino-s-triazin-2-yl)-amino}-2,2′-stilbenedisulfonate PVI: Polyvinyl imidosole having a weightaverage molecular weight of 20000 PVP: Polyvinyl pyrolidone polymerhaving a weight average molecular weight of 60000 PVNO: Polyvinylpyridine N-oxide polymer having a weight average molecular weight of50000 PVPVI: Copolymer of polyvinyl pyrolidone and vinyl imidazol,having a molecular weight of 20000 Dye fixative: Oligomer produced bythe condensation of imidazole and epichlorhydrin EMC: Ester modifiedcellulose PEO: Polyethylene oxide having a weight average molecularweight of from 100000 to 1000000 Clay: Smectite clay CMC: Sodiumcarboxymethyl cellulose MA/AA(1): Copolymer of maleic/acrylic acid,having a weight average molecular weight of from 50000 to 90000, whereinthe ratio of maleic to acrylic acid is from 1:3 to 1:4 QEA(1):bis((C₂H₅O)(C₂H₄O)n)(CH₃)—N+—C_(x)H_(2x)-N+—(CH₃)— bis((C₂H₅O)(C₂H₄O)n),wherein n = from 20 to 30, and x = from 3 to 8 QEA(2): sulphonated orsulphated bis((C₂H₅O)(C₂H₄O)n)(CH₃)—N+—C_(x)H_(2x)—N+—(CH₃)-bis((C₂H₅O)(C₂H₄O)n), wherein n = from 20 to 30, and x = from 3to 8 SRP(1): Anionically end capped polyesters SRP(2): Copolymer ofdimethylterephthalate/propylene glycol/methyl capped polyethyl glycolAmylase: Amylolytic enzyme having 1.6% by weight of active enzyme,supplied by NOVO Industries A/S under the tradename Termamyl 120TCellulase: Cellulytic enzyme having 0.23% by weight of active enzyme,supplied by NOVO Industries A/S under the tradename Carezyme Siliconeantifoam: Polydimethyl siloxane foam controller withsiloxane-oxyalkylene copolymer as dispersing agent, wherein the ratio ofsaid foam controller to said dispersing agent is from 10:1 to 100:1Soap: Sodium linear alkyl carboxylate which is derived from a mixture oftallow and coconut fatty acids, wherein the ratio of tallow to cocofatty acids is from 70:30 to 99:1 Perfume particle: Perfume particlecomprising a perfume and a carrier molecule Encap Perfume: Encapsulatedperfume

Example I

[0160] A sheet of water-soluble film (Chris-Craft M-8630 film) is placedover a series of 12 hexagonal shaped molds having six sides of equallength (each being 22.5 mm long), and having six corners having the sameinternal angle of 120°, the molds also have rounded (hemispherical-like)bottoms of a depth of 28 mm. A 1 mm thick layer of rubber is presentaround the edge of each mold. The molds have some holes in the moldmaterial to allow a vacuum to be applied. The molds are positioned inthree rows, each row having four molds. The molds are positioned in aninterlocking manner such that the edges of the adjoining molds touch.

[0161] A vacuum is applied to pull a single piece of film into the moldsso that the film is flush with the inner surface of the molds. Soliddetergent composition is poured into each mold so that the molds arefilled between 95% to 100%.

[0162] Next, another sheet of water-soluble film (Chris-Craft M-8630film) is placed over the top of the molds containing the solidcomposition, and is sealed to the first layer of fi lm by applying apiece of flat metal of a size to completely cover the whole series ofmolds, and heating that metal under moderate pressure onto the pieces ofrubber at the edges of the molds to heat-seal the two pieces of filmtogether. The piece of metal is typically heated to a temperature of140-146° C. and applied for up to 5 seconds.

[0163] The film is then cut to produce individual single pouches.

Example II

[0164] The following compositions are in accordance with the invention.Said compositions are enclosed within the pouches made of water-solublefilm (Chris-Craft M-8630 film). The pouches are made by the processdescribed in example I. Ingredient A B C D E F G H Alkoxylated 0.02 0.10.01 0.05 0.15 0.08 0.06 0.04 alcohol C28AS 0.5 0.6 1 0.2 C28E3 C28E5 35 7 2 4 6.5 5 3 C25E3S 1 0.5 0.8 1.2 FAS 2 0.5 0.2 1.5 0.2 0.8 1 0.6 LAS5 6 6.5 5 7 5.5 6 5.5 Carbonate 16 15 20 18 25 30 15 22 Silicate 0.050.1 0.08 0.2 0.05 0.1 0.2 0.15 Sulfate 22 20 17 15 14 12 20 16 CitricAcid 2.5 2 4 1.5 5 3 3.5 4 NaSKS-6 2 4 3.5 5 2.5 3 4 4.5 Zeolite A 15 2017.5 15 18 16 14 15 EDDS 0.1 0.5 0.05 0.15 0.25 0.2 0.1 0.15 HEDP 0.10.05 0.2 0.15 0.1 0.1 0.3 0.2 Mg Sulfate 0.5 0.4 0.3 0.3 0.4 0.2 0.50.25 Percarbonate 12 15 18 10 8 12 10 8 NAC_OBS 2 NOBS 2 TAED 2.5 2 1.53 1 5 Photobleach(1) 0.001 0.005 0.002 Photobleach(2) 0.005 0.001 0.002Brightener(1) 0.02 0.1 0.08 0.05 0.1 Brightener(2) 0.02 0.05 0.05 0.10.06 EMC 0.6 0.4 1.2 0.8 CMC 0.15 0.1 0.2 0.5 0.05 0.1 0.25 0.1 MA/AA(1)1.5 2.5 2 2.5 1 3 0.5 1.0 QEA(1) 0.5 0.3 1.2 1.0 0.4 1.0 QEA(2) 0.8 0.6SRP(1) 0.1 0.08 0.15 0.2 0.05 0.03 SRP(2) 0.15 0.1 Amylase 0.1 0.05 0.010.2 Cellulase 0.1 0.15 0.05 0.01 Silicone 0.05 0.1 0.02 0.08 0.01 0.050.03 antifoam Soap 0.6 0.5 0.1 0.05 0.3 0.4 0.5 0.5 Perfume 0.3 0.4 0.250.5 0.4 0.6 0.3 0.2 particle Encap perfume 0.1 0.2 Miscellaneous to toto to to to to to 100% 100% 100% 100% 100% 100% 100% 100%

Example III

[0165] The following detergent compositions are in accordance with theinvention. Said detergent compositions are enclosed within the pouchesmade of a water-soluble film (Chris-Craft M-8630 film). The pouches aremade by the process described in example I. Ingredient I J K L M N O PAlkoxylated 0.1 0.15 0.05 0.3 0.01 0.05 0.06 0.12 alcohol C28E5 5 3 43.5 4.5 2.5 C28E7 2 4 5 FAS 1 2 0.1 1 0.5 LAS 9 7 8 6 5 8 7 6 QAS(1) 11.5 0.5 QAS(2) 1 Carbonate 12 20 15 20 10 8 25 24 Silicate 0.1 3 0.05 54 1.2 1.5 1 Sulfate 30 20 25 18 30 27 12 16 Citric Acid 2 1 1.5 3 1 2NaSKS-6 3 4 2 STPP 22 25 20 25 Zeolite A 20 0.5 1 18 16 14 DTPA 0.4 0.50.3 EDDS 0.1 0.2 0.05 0.1 0.15 0.2 0.08 0.12 HEDP 0.15 0.1 0.2 0.12 0.050.05 0.1 0.08 Mg Sulfate 0.3 0.4 0.35 0.25 0.2 0.5 Percarbonate 10 6 7 712 11 10 8 NAC_OBS 1.5 NOES 0.8 TAED 1.2 0.5 1 1.8 0.8 2.4 Brightener(1)0.06 0.05 0.03 0.05 0.1 Brightener(2) 0.03 0.05 0.05 0.03 PEO 0.15 0.20.25 Clay 8 9 10 EMC 0.6 0.5 1.2 0.8 CMC 0.1 0.2 0.2 0.3 0.1 0.05 0.2MA/AA(1) 1 0.8 2 1.5 0.5 0.3 1.2 QEA(1) 0.5 0.1 0.4 QEA(2) 0.3 SRP(1)0.2 SRP(2) 0.2 Amylase 0.2 0.1 0.15 0.05 Cellulase 0.1 0.2 0.05 0.15Silicone 0.05 0.1 0.12 0.08 0.06 0.09 0.05 0.05 antifoam Soap 0.4 0.60.5 Perfume 0.3 0.4 0.25 0.5 0.4 0.35 particle Encap 0.4 0.3 PerfumeMiscellaneous to to to to to to to to 100% 100% 100% 100% 100% 100% 100%100%

Example IV

[0166] The following compositions are in accordance with the invention.Said compositions are enclosed within the pouches made of water-solublefilm (Chris-Craft M-8630 film). The pouches are made by the processdescribed in example I. Ingredient Q R S T U V W X C28E7 7 6 5 8 7 6.5 58 LAS 10 8 9 12 7 14 10 8 QAS(1) 0.5 0.8 0.4 1.0 1.2 0.5 0.6 0.8Carbonate 10 15 12 8 10 12 11 15 Silicate 3 5 4 6 5 4 3 2.5 Citric Acid1 2 1.5 1.2 2 0.8 1 1.5 STPP 15 20 18 25 20 16 15 22 Zeolite A 1.5 1 20.5 1.2 0.8 1 1 DTPA 0.4 0.5 0.6 DTPMP 0.6 0.5 0.5 0.4 EDDS 0.3 0.4 0.20.5 PVI 0.2 0.1 PVP 0.2 0.1 PVNO 0.08 0.1 0.2 0.1 0.12 0.05 0.12 0.18PVPVI 0.12 0.05 0.07 0.11 0.16 0.1 0.07 0.1 Dye fixative 0.1 0.07 EMC0.5 0.8 1.2 CMC 0.5 0.4 1 0.3 0.5 0.6 0.8 0.5 MA/AA(1) 1.5 3 1.2 2 2.51.5 2 2 QEA(1) 0.5 0.4 0.5 0.8 0.6 0.45 QEA(2) 0.4 0.6 SRP(1) 0.1 0.050.15 0.08 0.12 SRP(2) 0.05 0.1 0.05 0.14 Amylase 0.3 0.15 0.1 0.2 0.15Cellulase 0.2 0.1 0.4 0.05 0.1 Silicone 0.1 0.05 0.08 0.15 0.12 0.090.06 antifoam Perfume 0.4 0.3 0.25 0.5 0.3 0.2 Encap Perfume 0.4 0.4 0.2Miscellaneous to to to to to to to to 100% 100% 100% 100% 100% 100% 100%100%

What is claimed is:
 1. A process for preparing water-soluble pouchesfrom at least one sheet of water-soluble film, comprising the step ofshaping pouches from said water-soluble film in a series of molds,wherein said molds are positioned in an interlocking manner.
 2. Aprocess according to claim 1, whereby said molds have at least onestraight edge.
 3. A process according to claim 2, whereby the edges ofadjoining molds are substantially parallel.
 4. A process according toclaim 1 whereby said molds comprise less than two corners having aninternal angle of 90°.
 5. A process according to claim 1, whereby saidmolds comprise at least one corner having an internal angle greater than90°.
 6. A process according to claim 1 whereby said molds comprise atleast 5 corners.
 7. A process according to claim 1 whereby the shape ofsaid molds is a polygon.
 8. A process according to claim 7, whereby theshape of said molds is a hexagon.
 9. A process according to claim 1whereby said water-soluble pouch contains a detergent composition.
 10. Aprocess according to claim 1 whereby said water-soluble film comprisespolyvinyl alcohol.
 11. A process according to claim 1 wherein themaximum variation in the distance between adjoining molds is less than200%.
 12. A water-soluble pouch, obtainable by the process of claim 8.13. A mold, or series of molds, for a water-soluble pouch, wherein theshape of said mold, is a hexagon.